Acidulate composition and methods for making and utilizing the same

ABSTRACT

A baking additive for enhancing the shelf-life and maintaining the volume of a baked product, and methods for producing and using the same. The baking additive comprises a blend of an non-encapsulated acidulate and an acidulate having a fat-based encapsulating coating that is degradable by heat. The combination of the encapsulated and non-encapsulated provides strategic release of the acidulates throughout the baking process such when the baking additive is added to a dry dough mix, the acidulates can sufficiently decrease the pH of the dry dough mix to prevent microbial contamination without interfering with glutton elasticity or the chemical leavening system.

PRIORITY

This U.S. Utility Patent application is a continuation application of,and claims priority to, copending U.S. patent application Ser. No.12/175,371, filed Jul. 17, 2008, contents of which are herebyincorporated by reference in its entirety into this disclosure.

BACKGROUND

Dough-based baked food products having a high water content (e.g.,tortillas, bread, bagels and other bakery goods) are particularlysusceptible to food spoilage problems caused by the unwanted growth ofbacteria, yeasts and molds. In order to prevent microbial spoilage, suchproducts are often treated with preservatives to inhibit yeast,bacteria, and/or mold growth and thereby extend the shelf life of theproduct. Such preservatives may include calcium propionate, sorbic acid,and benzoic acid, and typically function by preventing microbes fromproducing the requisite energy needed to grow and reproduce.

An acidic environment in foodstuffs has been found to actsynergistically with these preservatives, showing an increase inshelf-life over food products solely containing the preservatives at aneutral pH. In order to stabilize the antimicrobial preservatives thatgenerally perform better in high acidity levels, it is known to addacidulates, such as fumaric acid, to the food product to reduce pHlevels and provide an optimal acidic environment. Specifically,acidulates are added to foodstuffs to reduce the pH level of a dough toat or near the acid dissociation constant (“pK_(a)”) of the particularpreservative also contained therein. When the pH of the dough approachesthe pK_(a) of the added preservative, the conjugated acid form of thepreservative is mostly available and therefore optimally effective atreducing microbial growth.

Adding an acidulate, such as fumaric acid, citric acid, malic acid,lactic acid, or ascorbic acid, to dry dough mixtures has proven tosuccessfully increase the shelf life of food products in most cases.However, the addition of such acidulates to the dry mix presentsproblems for the resulting baked goods. For example, when suchacidulates, or food acids, are added to dry bread mix, a negative effectis seen on the proteins (gluten) in the bread end product. This occursbecause the elasticity of gluten is influenced by pH and a finishedbaked product resulting from an acidic dough tends to exhibit a densersize per mass, thereby resulting in a baked product having a decreasedheight and diameter.

Further, the addition of acidulates to dough can also have a negativeeffect on the chemical leavening system therein, resulting in low volumebaked products. Typically, chemical leavening systems include aleavening acid and a leavening base (i.e. sodium bicarbonate). In mostleavened products, the base is added to the dry dough mix and the acidportion is added just prior to baking. Accordingly, the leavening acidand base ideally do not react until the baking process (i.e. when thedough is heated), thereby preventing the formation of carbon dioxideuntil the dough cell walls are prepared to expand and trap the gastherein.

However, when an acidulate is added for preservation purposes, theacidulate dissolves at the initial stages of mixing and immediatelybegins to react with the dissolved leavening base. In this manner, theformation of carbon dioxide occurs prematurely and the leavening base isfully reacted prior to the baking stage. As a result, during the bakingstage when the leavening gases should be produced, an insufficientamount of leavening base exists within the batter to react with theleavening acid and the rising capability of the dough is depleted.Accordingly, the addition of preservative acids to the dry dough mix canlead to many undesirable physical qualities in the finished product,some of which have been previously mentioned above.

In order to avoid some of the problems associated with prematurelyacidifying dough, acidulates having low solubility have been commonlyused. The advantage of using an acidulate having a low solubility isthat the acidulate does not dissolve quickly into the dough mix duringmixing and baking and, thus, decreases the pH of the mix more slowlythan acidulates with higher solubilities. Fumaric acid is an example ofsuch an acidulate and is commonly selected for its low solubility. If alow pH is delayed, a reduction in the deleterious effects to the glutenand the chemical leavening system will result. However, despite the lowsolubility of fumaric acid and other similar acidulates, even theseacidulates tend to dissolve prematurely and sufficiently lower the pH ofthe dough mix such that some negative effects are produced in thefinished product.

In an attempt to further delay the dissolution of acidulates into adough mix, larger particle sizes of the acidulates have been employed,often ranging up to 300 microns. As is commonly known, the size of aparticle is inversely proportional to the solubility of the particle(e.g., the larger the particle size, the slower the rate ofdissolution). In addition, it is known to encapsulate the acidulate in acoating to further delay the dissolution of the fumaric acid into thedough mix.

Nevertheless, by increasing the resistance of the fumaric acid todissolution through use of an increased particle size or usingencapsulation techniques, the likelihood is greatly increased that theconcentration of fumaric acid within the dough mix will be insufficientto adequately reduce the acidity of the dough mix to facilitate theactivity of the preservative. In this manner, while the integrity of thegluten and chemical leavening system is left in tact, the product doesnot exhibit a satisfactory shelf-life due to its susceptibility tomicrobiological contamination. It has proven exceedingly difficult toachieve the desired time-dissolution profile for dough formation andbaking with both of these methods. Accordingly, it is desirable toobtain a compound and/or a method that can be used to maintain orincrease an extended “shelf-life” of the product in addition toincreasing the volume of the end-product baked good.

SUMMARY

Compositions for enhancing the shelf-life and maintaining the volume ofa baked product, as well as methods for producing and using the same.Certain compositions comprise a baking additive comprising a blend of afirst quantity of acidulate comprising acidulate particles and a secondquantity of acidulate, wherein each the particles of the first quantityof acidulate each comprise an edible, heat degradable encapsulatingcoating. The first and second quantities of acidulate may comprisecitric acid, malic acid, fumaric acid, potassium citrate, sodiumcitrate, lactic acid and/or ascorbic acid. When the blended compositionof the first and second quantities of particles are added to adough-based product, the composition is capable of decreasing the pH ofa dough-based product.

The first quantity of acidulate and the second quantity of acidulate maybe combined at a ratio of about 1:1 by weight. Further, the thickness ofthe coating of each of the particles of the first quantity of acidulatemay vary depending on the desired rate of release of the acidulatetherein. For example, and without limitation, the particles of the firstquantity of acidulate may each comprise a coating of between about 0.1%to about 70.0% of the total weight of the coated particle. In addition,the encapsulated coating may further comprise a fat-based coating.Further, in at least one example, the encapsulating coating of each ofthe particles of the first quantity of acidulate may be comprised of atleast two fats. For example, the fat-based coating may comprise a firstsolidified oil and a second solidified oil that may be combined at aratio of about 1:1 by weight or any other ratio that is sufficient toform a sufficient fat-based coating to encapsulate each of the particlescomprising the first acidulate. In addition, the melting point of thefat-based encapsulating coating may be between about 138 degreesFahrenheit and about 150 degrees Fahrenheit. In another example, themelting point of the fat-based encapsulating coating may be betweenabout 105 degrees Fahrenheit and about 122 degrees Fahrenheit.

A method for producing the above-described baking additive compositionis also disclosed. One example of the method comprises the followingsteps: providing a first quantity of acidulate formed into a pluralityof acidulate particles; providing a second quantity of acidulate;encapsulating each of the particles of the first quantity of acidulatewith an encapsulating coating; and blending the first quantity ofacidulate with the second quantity of acidulate not encapsulated withina coating to form a composition. Further, in at least one example, thestep of encapsulating the particles of the first quantity of acidulatewith an encapsulating coating further comprises the step of performingan encapsulation of each of the particles of the first quantity ofacidulate particles using an encapsulating technique such as hot-meltencapsulation, spray-drying, coacervation, fluid bed coating, liposomeentrapment, or any other encapsulation technique known in the art.Additionally, the method of producing the baking additive compositionmay comprise the steps of mixing a first fat with a second fat; meltingthe first fat and the second fat such that the first fat and the secondfat combine in a fluid state; and coating the first quantity ofacidulate particles with the fluid state.

Further, methods for producing a baked product having containing apreservative are disclosed. These methods comprise the steps of:providing the above-described baking additive; adding the bakingadditive to a dry dough mix for a baked product, thereby reducing the pHof the dry dough mix and activating at least one preservative containedtherein; adding at least one liquid ingredient to the dry dough mix andprocessing the same to obtain a dough batter; an heating the doughbatter to above a first temperature, thereby forming at least one porein each of the encapsulating coatings surrounding each of the particlesof the first quantity of acidulate so that at least a portion of theacidulate of the first quantity of acidulate are allowed to leachthrough the at least one pore in each of the encapsulating coatings. Inaddition, the step of processing the dry dough mix may further comprisemixing the dry dough mix. Further, in at least one example, the doughmix may further comprise a leavening system. In this at least oneexample, the leavening system may comprise a chemical leavening system,yeast-based leavening system, or any other leavening system used in theculinary arts. In addition, the baked product may comprise a tortilla.

DESCRIPTION OF THE FIGURES

FIG. 1A shows a photograph illustrating a tortilla from the controlbatch of specimens not containing an acidulate at the end of a 6-monthperiod;

FIG. 1B shows a photograph of a tortilla from a second batch ofspecimens containing raw acidulate at the end of a 6-month period;

FIG. 1C shows a photograph of a tortilla from a third batch of specimenscontaining an embodiment of the acidulate composition disclosed hereinat the end of a 6-month period;

FIG. 2 shows a line graph illustrating the pH to volume ratio of severaltortilla doughs each made comprising different embodiments of thefumaric acid composition; and

FIG. 3 shows a bar graph illustrating the difference between the volumeof the end-product baked good resulting from the tortilla dough ofSeries 2 of FIG. 3 and data regarding other tortilla doughs comprisingdifferent leaveners and raw acidulates published in Chemical LeaveningAgents by Ernst Brose et al. (Budenheim/H. Schmidt Mainz, 1996).

DETAILED DESCRIPTION

Reference will now be made to various embodiments and specific languagewill be used to describe the same. It will nevertheless be understoodthat no limitation of scope is intended by the description of theseembodiments. Throughout the specification and claims, percentages andratios are by dry weight and temperatures are in degrees Fahrenheit,unless otherwise indicated.

Food manufacturers strive for the perfect balance of shelf-lifestability and product quality. As previously noted, dough-based bakedfood products that are high in water content exhibit an inherentsusceptibility to microbial contamination. However, particularly withrespect to baked goods such as tortillas, the moisture content of thetortilla dough and, thus, the tortilla baked product, is directlycorrelative to producing an end product that exhibits a mouth feel,taste and pliability that is pleasing to the end consumer, as well asthe ability of the end product to exhibit shelf life stability.Specifically, the total water content in the tortilla dough should be inthe range of between about 30% and about 55% by weight of the dough.Further, tortillas exhibiting desirable properties typically containfrom about 30% to about 40% water content with respect to the totalweight of the end product.

It has been determined that the shelf-life and end volume of bakedproducts having high residual water contents can be increased by addingan acidulate composition to the dry dough mix as described herein. Theacidulate composition comprises a blend of encapsulated andnon-encapsulated (or “raw”) acidulate, and the addition of thecomposition to a dough mix has shown to increase the longevity of theend product's shelf-life beyond that which is seen with solely theaddition of either encapsulated acidulate or raw acidulate. Theseresults can be attributed, at least in part, to the combination of theencapsulated acidulate and the raw acidulate. Any acidulate known in theart may be used, including, without limitation, citric acid, malic acid,fumaric acid, potassium citrate, sodium citrate, lactic acid, and/orascorbic acid, so long as the composition comprises a blend of raw andencapsulated acidulate. For example, in at least one embodiment, rawfumaric acid under the trade name Fumaric Acid from Tate & Lyle inLondon, England can be used.

Further, it is not necessary that the raw acidulate and the encapsulatedacidulate comprise the same acidulate compound. In at least one example,the raw acidulate of the acidulate composition may comprise fumaric acidand the encapsulated acidulate of the acidulate composition may comprisecitric acid. In an alternative example, the raw acidulate may comprise ablend of two or more acidulate compounds, such as and withoutlimitation, a combination of citric acid and malic acid, and theencapsulated acidulate of the acidulate composition may comprise citricacid, fumaric acid and potassium citrate. It will be understood that anycombination of acidulates may be used in conjunction with the acidulatecomposition so long as a portion of the acidulate comprises rawacidulate and a portion comprises encapsulated acidulate.

When the acidulate composition is added to a dry dough mix, a definedamount of raw acidulate is allowed to react at an early stage with thedry dough mix in a controlled manner. Further, the encapsulatedacidulate is prevented from early reaction with available basiccompounds (i.e. the leavening base). By way of a non-limiting example,the acidulate composition may comprise about 50% of encapsulated fumaricacid (by dry weight) and about 50% of raw fumaric acid (by dry weight);however, it will be appreciated that any ratio of encapsulated acidulateand raw acidulate may be added so long as both components are present insufficient amounts to support the antimicrobial effects of thepreservative.

The particles (both raw and encapsulated) comprising the acidulatecomposition may comprise a mean particle size of less than about 1,000microns (pre-coating with respect to the encapsulated portion). In atleast one embodiment, about 10% of the total composition comprises aparticle size of less than about 150 microns (pre-coating) and about 90%of the total acidulate blend comprises a particle size of less than 600microns (pre-coating).

As previously described, in addition to the raw acidulate, thecomposition further comprises encapsulated acidulate. The encapsulatedacidulate particles may comprise any mean particle size between about 5microns and about 1,000 microns and, in at least one embodiment, theencapsulated acidulate comprises a mean particle size between about 200microns and about 300 microns. The encapsulated acidulate comprisesacidulate coated in a heat-degradable coating. In at least oneembodiment, the coating comprises a fat-based coating. Alternatively,the coating may comprise a fat-based coating having a plurality ofcrystals disposed in a mesh-like configuration. The encapsulatedacidulate may be encapsulated using methods commonly known in the art,such as hot-melt encapsulation, spray drying, extrusion, coacervation,fluid bed coating, or liposome entrapment.

It will be appreciated that any type of edible, heat-degradable coatingmay be used, so long as the coating is capable of maintaining an amountof the acidulate within the capsule prior to being subjected to heat.For example, the coating may be selected from the group consisting oflipid materials such as, but not limited to, mono-, di- andtriglycerides, waxes, and organic esters derived from animals,vegetables, minerals and modifications. Some examples include soybeanoil, cottonseed oil, canola oil, camuba wax, beeswax, tallow, palmkernel oil and mixtures thereof.

The encapsulated acidulate may comprise any thickness of coating. Inreference by total weight of the encapsulated acidulate, the acidulatemay be present in the amount of greater than about 0.001% by weight andthe coating may be present in the amount of less than about 99.999% byweight. However, it will be understood that when the coating used toencapsulate the acidulate comprises more than about 1.0% of the overallbaking mix to which the acidulate composition is added, the underlyingformula of the baking mix may be negatively affected and the end bakedproduct may not produce optimal characteristics. When the encapsulatedacidulate comprises between about 0.1% to about 70.0% coating, by weightand, accordingly, from about 99.9% to about 30.0% acidulate, by weight,such negative affects are typically avoided.

The thickness of the coating on each of the encapsulated acidulateparticles may vary from particle to particle, or be consistentthroughout all of the encapsulated acidulate particles included in theacidulate composition. For example, the thickness of the coating on eachof the encapsulated acidulate particles may be designed to enable asteady release of acidulate into the baking mix when heat is appliedover time during the baking process.

The melting point of each capsule is dependent upon the specific typesof fat(s) used therein as well as the thickness of the coating. In oneembodiment, the capsule is comprised of at least two different fatproducts and exhibits a melting point of between about 138 degreesFahrenheit and about 150 degrees Fahrenheit. In an additionalembodiment, a mixture of about 50% Stable Flake-S solidified oil andabout 50% Trans Advantage solidified oil is used to form the coating. Inthis embodiment, the coating may exhibit a melting point between about105 degrees Fahrenheit and about 122 degrees Fahrenheit.

Now referring to the preparation of the acidulate composition as awhole, the fat-based coating for the encapsulated acidulate component isprepared by mixing the selected fat(s) with any desired additives andthereafter melting the fat to a fluid state. In the embodiment wheremore than one fat is used to form the capsule, the different fats aremixed together in the desired ratio and thereafter melted such that thefats combine in a fluid state. For example, and without limitation,Stable Flake-S solidified oil and Trans Advantage solidified oil may bemixed together at a ratio of about 1:1 by weight, and thereafter meltedsuch that the two types of fat combine in a liquid state.

After the fat is in a liquid form, the liquid is used to prepare theencapsulated acidulate. Specifically, the desired amount of acidulate isencapsulated with the fat mixture by any encapsulation technique knownin the art. The amount of acidulate to be encapsulated is dependent uponthe desired ratio of encapsulated acidulate to raw acidulate containedwithin the acidulate composition, as well as the desired thickness ofthe coating. After the encapsulated acidulate has been prepared, rawacidulate is added to the encapsulated acidulate at the desired ratioand combined therewith such that the raw acidulate and the encapsulatedacidulate are evenly dispersed with one another. As previouslydescribed, the ratio of raw acidulate to encapsulated acidulate maycomprise any proportion that produces beneficial results, and in atleast one embodiment, the raw acidulate and the encapsulated acidulateare combined at a ratio of 1:1 (by weight, pre-coating).

The acidulate composition can be added directly to the raw ingredientsfor preparing baked goods. For example, the acidulate composition can beadded to a dry dough mix at about 0.1% to about 1.0% of the total weightof the raw ingredients on a dry weight basis. In at least oneembodiment, the acidulate composition is present in the dry dough mix inan amount of about 0.25% to about 5.0% on a dry weight basis. Forexample, the acidulate composition can be incorporated into a flourdough by adding it to the flour or to the moist dough.

The blend of the acidulate composition enables the acidulate to beavailable to react with a dough mixture containing a preservative in twodistinct phases. Specifically, in the first phase the raw acidulateportion of the composition is immediately available to reduce the pH ofthe dough mix to near or at the pK_(a) value of the preservativecontained within the dough mix. Accordingly, when the acidulatecomposition is added to a dough mixture, the raw acidulate isimmediately available to decrease the pH of the dough mix and therebyoptimize the antimicrobial effects of the preservative contained thereinduring the mixing and proofing stages. It will be recognized that theacidity resulting from the addition of the raw acidulate component ofthe acidulate composition may cause a reaction with some of theleavening base contained within the mix. However, this reaction can beminimized by controlling the amount of raw acidulate added to the doughmix. Accordingly, due to the decreased pH of the dough, the dough can beadequately processed through mixing, kneading or and/or machining priorto baking with decreased risk with respect to microbial contamination.

The second phase of acidulate availability is initiated by the heat fromthe baking process. After the dough has been adequately processed, thedough batter is subjected to heat and the capsules containing theencapsulated acidulate undergo gradual degradation. In one embodiment,the degradation of the capsule weakens the capsule structure and formsat least one pore therein. The pore allows the acidulate containedwithin the capsule to be released from the capsule and into the bakingproduct at a controlled rate. Alternatively, depending on the thicknessand/or composition of the coating, the heat degradation may result in aplurality of pores in the coating such that the acidulate can leach fromwithin the capsule at an increased rate.

Because the second phase of acidulate is released into the dough onlyafter the dough is heated, the second phase of acidulate has little, ifany, affect on glutton extensibility or the leavening reaction. By wayof example and without limitation, where the dough mixture comprises ayeast-based leavening system, the addition of a large amount of rawacidulate to the dough mixture will detrimentally decrease the pH of thedough mixture, thereby killing the yeast and preventing the productionof carbon dioxide that is necessary for leavening the dough. However,when the acidulate composition described herein is employed, the yeastis capable of leavening the dough throughout the proofing stage (untilthe dough is heated to about 120° F. and the yeast is killed), as the pHof the dough mixture is not substantially decreased. Accordingly, theacidulate composition described herein has a minimal effect (if any) onthe production of carbon dioxide of the yeast.

In another example, the dough mixture may comprise a chemical leaveningsystem comprised of sodium bicarbonate and a leavening acid. Inconventional systems where raw acidulates are employed to work inconcert with a preservative, because of the competition between theacidulate and the leavening acid to react with the sodium bicarbonate,it is not uncommon for formulas to call for an increased amount ofsodium bicarbonate to ensure that a sufficient amount of sodiumbicarbonate is present to react with both the acidulate and theleavening acid such that adequate leavening is achieved. In this manner,the sodium bicarbonate functions as a buffer to compensate for thedecreased pH resulting from the addition of the raw acidulate to thedough mixture.

The addition of the acidulate composition described herein allows forthe reduction in the amount of sodium bicarbonate added to the doughmixture as only a limited amount of raw acidulate is available to reactwith the sodium bicarbonate prior to completion of the leaveningprocess. As a result, the acidulate composition has a minimal effect (ifany) on the rate of reaction between the sodium bicarbonate and theleavening acid, as the encapsulated acidulate is not available to reactuntil after the leavening process is substantially complete. Thereafter,when the dough mixture is heated to the desired temperature, thecapsules of the encapsulated acidulate degrade and the acidulatecontained within the capsules is allowed to leach into the dough. As theencapsulated acidulate is not released into the dough until after theleavening system has reacted, the finished baked product exhibitsdesirable volume, taste, and microbial-resistant characteristics.

Further, unlike the first phase, the release of acidulate in the secondphase may occur over a period of time. The release rate of the acidulatefrom the capsules is dependent upon several factors. Primarily, and aspreviously noted, it will be appreciated that the rate and manner inwhich the coating degrades is dependent on the composition and thicknessof the encapsulating coatings. Accordingly, the composition and/ordimensions of the capsule may be manipulated to achieve the desiredrelease rate. For example, fats comprising a higher melting pointdegrade slower when subjected to lower temperatures and thereby releasethe acidulate contained therein at a slower rate. Similarly, fatscomprising a lower melting point typically degrade faster.

The thickness of the coating can affect the rate of acidulate releasefrom within a capsule (e.g., the thicker the coating, the longer thecoating may take to degrade or the higher the temperature may berequired). Accordingly, coating thickness may be manipulated dependingon the temperatures required to bake a specific baked goods. Forexample, the coating thickness of the encapsulated particles may beincreased when the acidulate composition is used in conjunction withbaked goods that require baking at higher temperatures. In this manner,the coating thickness can better withstand the higher bakingtemperatures and maintain a controlled release of acidulate.

Furthermore, the manner in which the capsule degrades is another factorthat can affect release rate of acidulate from within the capsule.Depending on what compounds the capsule comprises, the capsule maydegrade to form one pore or a plurality of pores. As previously noted,the number and size of pore formation affects the release rate of theacidulate from the capsule. Accordingly, it will be appreciated thatthese factors may be controlled to produce the desired rate of releaseof the acidulate into the baked good.

It will be appreciated that the degradation of the capsules is notreversible. Accordingly, after the baking process, each capsulecomprises at least one pore through which the encapsulated acidulate iscapable of traversing. As previously mentioned, most dough-based foodproducts comprise a relatively high water content. Accordingly, theacidulate contained within each of the partially degraded capsules issubjected to an osmotic pressure exerted by the water content of thedough-based food product. Over time, this osmotic pressure facilitatesthe leaching of the acidulate from within the partially degradedcapsules into the food product. As the acidulate slowly leaches into thebaked food product, the acidulate decreases (or maintains, depending onthe rate the acidulate is released from the capsule) the pH of the bakedgood, thus promoting the efficiency of the preservative.

Due to the distinct phases in which the acidulate is available todecrease the pH of the dough mix, the leavening system is not inhibitedand full leavening dough may be achieved. Consequently, the addition ofthe acidulate composition to a dough mixture produces a baked productexhibiting a superior volume and having a longer shelf life than thedough products of the prior art. Further, use of the acidulatecomposition enables for the baked product to contain a reduced amount ofsodium bicarbonate. Because the sodium bicarbonate is not significantlydepleted by the presence of a large amount of acidulate in the dry mix,extra amounts of sodium bicarbonate need not be added to the dough mix,thereby decreasing the salt content and ingredient overhead of the endproduct. This is primarily because the first phase of fumaric acid isregulated and the second phase of acidulate is not released until afterthe leavening process has occurred.

The following are examples of compositions prepared using the fumaricacid composition in tortilla doughs. The examples are also compared totortilla doughs prepared using other food acidulates, and the Figuresdescribed below serve to demonstrate the improved results describedherein. The examples are not meant to limit the scope hereof, as issolely defined by the claims.

Example 1

Tests were run using the below-described method of preparation andingredients to illustrate the effects of including the acidulatecomposition in a flour tortilla formulation. A control flour tortillabatch was prepared from the following ingredients:

TABLE 1 Ingredients Grams Weight % Flour 1004.6 61.84 Salt 15 0.9234Shortening 60 3.6936 Leavening 11.8 0.7264 Sodium Propionate 4 0.2462Potassium Sorbate 4 0.2462 SSL 5 0.3078 Cysteine (reducing agent) 0.030.0018 Water 520 32.01

The ingredients listed in Table 1 were combined at 100° F. The water andflour mixture was mixed for 2 minutes at a low speed with a dough hook.The dough was allowed to stand for 5 minutes and then divided into50-gram balls that were heat pressed at 175° F. for 10 seconds. The rawtortillas were then baked on a griddle at 400° F. for 30 seconds on eachside, and subsequently cooled.

Further, a second batch of tortilla specimens were prepared containingraw fumaric acid as the acidulate. The procedure used to prepare thesecond batch of specimens was the same as the control batch, except thatthe following ingredients were used:

TABLE 2 Ingredients Grams Weight % Flour 1000 61.56 Salt 15 0.9234Shortening 60 3.6936 Leavening 11.8 0.7264 Raw Fumaric Acid 4.6 0.2832Sodium Propionate 4 0.2462 Potassium Sorbate 4 0.2462 SSL 5 0.3078Cysteine (reducing agent) 0.03 0.0018 Water 520 32.011

A third batch of tortilla specimens were prepared containing theacidulate blend described herein. Specifically, the acidulate of thethird batch of tortillas comprised a fumaric acid blend comprising about50% by weight raw fumaric acid and about 50% by weight encapsulatedfumaric acid. In addition, the capsule of the encapsulated fumaric acidexhibited a coating thickness of about 50% by weight (as compared to theencapsulated fumaric acid contained therein) and comprised StableFlake-S oil and Trans Advantage oil combined at a ratio of about 1:1.

The procedure used to prepare the third batch of specimens is the sameas in Table 1, except that the following ingredients were used:

TABLE 3 Ingredients Grams Weight % Flour 1000 61.56 Salt 15 0.9234Shortening 60 3.6936 Leavening 11.8 0.7264 Fumaric Acid Composition 4.60.2832 Sodium Propionate 4 0.2462 Potassium Sorbate 4 0.2462 SSL 50.3078 Cysteine (reducing agent) 0.03 0.0018 Water 520 32.011

Tortillas from each test batch were evaluated after baking for volume,eating quality, and microbial growth. Thereafter, tortilla specimensfrom of each batch were heat sealed in cellophane bags, bagged inZIPLOCK® freezer pouches and stored at about 77° F. All test batches oftortilla samples were checked periodically for visual signs of microbialgrowth, volume reduction, and overall appearance over a 6-month period.

As illustrated by FIG. 1A, by the end of the 6th month, visible signs ofmold were present on the control flour tortillas of the first batch.Further, as shown in FIG. 1B, the second batch containing solely rawfumaric acid produced tortillas having low volumes due to the rawfumaric acid competing with the leavening system. In addition, thetortillas of the second batch also displayed visual signs of microbialgrowth, albeit to a lesser extent than the control tortillas of thefirst batch, as well as undesirable texture and off-flavor at the end ofthe 6-month period. However, as illustrated in FIG. 1C, the tortillaspecimens of the third batch containing the acidulate compositiondescribed herein had not molded by the end of the 6-month test.Additionally, the tortillas containing the disclosed acidulatecomposition exhibited sufficient volume and had no off-flavor orundesirable texture at the end of the 6-month period or anytime afterbaking.

Example 2

Now referring to FIG. 2, several different ratios of raw fumaric acidversus encapsulated fumaric acid were added to the tortilla doughsprepared according to the procedure and ingredients described inconjunction with Table 3. The pH to volume ratio of the resultingtortillas were graphed as a function of these ratios. Specifically, thedata set comprising Series 1 was based on a first set of tortilla doughsprepared according to the procedure and ingredients described inconjunction with Table 3 and the data set comprising Series 2 was basedon a second set of tortilla doughs prepared according to the procedureand ingredients described in conjunction with Table 3. The pH of thedoughs is indicative of the dissolution of the acid; the lower the pH,the more acid has been dissolved into the dough. The two lines shownrepresent two series of doughs prepared as indicated above, with theexception that each plot point comprises a different ratio of rawfumaric acid to encapsulated fumaric acid.

The ratios shown on the X-axis correspond to the different ratios offumaric acid compositions used to prepare the tortilla doughs. As seenin FIG. 2, the optimum pH and volume for both series of formulationswere the tortilla doughs comprising about a 1:1 ratio of encapsulatedfumaric acid to raw fumaric acid.

FIG. 3 illustrates the difference in volume developed from the tortilladoughs comprising a 1:1 ratio of encapsulated fumaric acid to rawfumaric acid of Series 2 as compared to tortilla doughs comprising otherleaveners and acidulates known in the art. As is illustrated in FIG. 3,the tortilla dough of Series 2 comprising the fumaric acid blendcomposition results in an end-product that exhibits an increased volumeover tortilla doughs containing raw acidulates.

While various embodiments of baking additive compositions, and methodsfor producing and using such compositions have been described inconsiderable detail herein, the embodiments are merely offered by way ofnon-limiting examples of the disclosure described herein. Manyvariations and modifications of the embodiments described herein will beapparent to one of ordinary skill in the art in light of thisdisclosure. It will therefore be understood by those skilled in the artthat various changes and modifications may be made, and equivalents maybe substituted for elements thereof, without departing from the scope ofthe disclosure. For example, it will be understood that any type ofacidulate may be employed in the acidulate composition disclosed herein.Indeed, this disclosure is not intended to be exhaustive or to limit thescope of the disclosure. The scope of the disclosure is to be defined bythe appended claims, and by their equivalents.

Further, in describing representative embodiments, the disclosure mayhave presented a method and/or process as a particular sequence ofsteps. However, to the extent that the method or process does not relyon the particular order of steps set forth herein, the method or processshould not be limited to the particular sequence of steps described. Asone of ordinary skill in the art would appreciate, other sequences ofsteps may be possible. Therefore, the particular order of the stepsdisclosed herein should not be construed as limitations on the claims.In addition, the claims directed to a method and/or process should notbe limited to the performance of their steps in the order written, andone skilled in the art can readily appreciate that the sequences may bevaried and still remain within the spirit and scope of the presentdisclosure. It is therefore intended that the disclosure will include,and this description and the appended claims will encompass, allmodifications and changes apparent to those of ordinary skill in the artbased on this disclosure.

1. A baking additive comprising: a first quantity of acidulatecomprising acidulate particles; a second quantity of acidulate; anedible, heat degradable, encapsulating coating surrounding each of theparticles of the first quantity of acidulate, the encapsulating coatingbeing at least partially degradable by heating the coating to apredetermined temperature; and wherein the second quantity of acidulateof the baking additive is capable of decreasing the pH of a dough mixupon adding the baking additive with the first and second quantities ofacidulate to the dough mix and wherein the first quantity of acidulateof the baking additive is capable of decreasing the pH of a dough basedproduct that is obtained from heating the dough mix with the bakingadditive over the predetermined temperature.
 2. The baking additive ofclaim 1, wherein the first quantity of acidulate is selected from agroup consisting of citric acid, malic acid, fumaric acid, potassiumcitrate, sodium citrate, lactic acid, and ascorbic acid.
 3. The bakingadditive of claim 1, wherein the second quantity of acidulate isselected from a group consisting of citric acid, malic acid, fumaricacid, potassium citrate, sodium citrate, lactic acid, and ascorbic acid.4. The baking additive of claim 1, wherein the first quantity ofacidulate and the second quantity of acidulate comprise fumaric acid. 5.The baking additive of claim 1, wherein the first quantity of acidulateand the second quantity of acidulate are combined at a ratio of about1:1 by weight.
 6. The baking additive of claim 1, wherein theencapsulating coating of each of the particles of the first quantity ofacidulate comprises between about 0.1% to about 70.0% of the totalcoated particle weight.
 7. The baking additive of claim 1, wherein theencapsulating coating comprises a fat-based coating.
 8. The bakingadditive of claim 7, wherein the fat-based coating comprises at leasttwo fats.
 9. The baking additive of claim 8, wherein the fat-basedcoating comprises a first solidified oil and a second solidified oil.10. The baking additive of claim 9, wherein the first solidified oil andthe second solidified oil are combined at a ratio of about 1:1 byweight.
 11. The baking additive of claim 7, wherein the melting point ofthe fat-based coating is between about 138 degrees Fahrenheit and about150 degrees Fahrenheit.
 12. The baking additive of claim 7, wherein themelting point of the fat-based coating is between about 105 degreesFahrenheit and about 122 degrees Fahrenheit.
 13. The baking additive ofclaim 8, wherein the melting point of the fat-based coating is betweenabout 105 degrees Fahrenheit and about 122 degrees Fahrenheit.
 14. Amethod of producing a preservative enhancing baking additive comprisingthe steps of: providing a first quantity of acidulate comprisingacidulate particles; providing a second quantity of acidulate comprisingacidulate particles; encapsulating the particles of the first quantityof acidulate with an edible, heat degradable coating; and blending thefirst quantity of acidulate with the second quantity of acidulate toform a composition; wherein the acidulate particles of the secondquantity of acidulate are not encapsulated within a coating.
 15. Themethod of claim 14, wherein the first quantity of acidulate and thesecond quantity of acidulate comprise fumaric acid.
 16. The method ofclaim 14, wherein the coating comprises a fat-based coating.
 17. Themethod of claim 16, wherein the fat-based coating comprises at least twofats.
 18. The method of claim 17, wherein the step of encapsulating theparticles of the first quantity of acidulate with an edible, heatdegradable coating further comprises the steps of: mixing a first fatwith a second fat; melting the first fat and the second fat such thatthe first fat and the second fat combine into a fluid state; and coatingthe first quantity of acidulate with the fluid state.
 19. The method ofclaim 14, wherein the step of encapsulating each of the particles of thefirst quantity of acidulate with an edible, heat degradable coatingfurther comprises the step of using an encapsulation technique selectedfrom the group consisting of hot-melt encapsulation, spray drying,extrusion, coacervation, fluid bed coating, and liposome entrapment. 20.A method of producing a baked product containing a preservative, themethod comprising the steps of: providing a first quantity of acidulatecomprising acidulate particles, providing an edible, heat degradable,encapsulating coating surrounding each of the particles of the firstquantity of acidulate, the coating being at least partially degradableby heating to a predetermined temperature; providing a second quantityof acidulate comprising acidulate particles, each acidulate particle ofthe second quantity of acidulate not comprising a coating thereon, andblending the first quantity of acidulate and the second quantity ofacidulate together to form a baking additive; adding the baking additiveto a dough mix for a baked product, wherein the second quantity ofacidulate reduces the pH of the dough mix to increase the antimicrobialeffect of the preservative contained therein; processing the dough mixto obtain a dough batter; heating the dough batter above thepredetermined temperature, thereby causing the gradual release of thefirst quantity of acidulate by degrading the encapsulating coating toreduce the pH of the baked product.
 21. The method of claim 20, whereinthe dough mix further comprises a leavening system comprising a yeast,and the method further comprises the step of proofing the dough battersuch that the leavening system leavens the dough batter.
 22. The methodof claim 20, wherein the dough mix further comprises a leavening systemcomprising a leavening acid and a leavening base and wherein during thestep of processing the dough mix to obtain a dough batter, the coatingon each of the particles of the first quantity of acidulate prevents thefirst quantity of acidulate from reacting with the leavening base. 23.The method of claim 20, wherein the baked product comprises a tortilla.24. The method of claim 20, wherein the predetermined temperaturecomprises a temperature between about 105 degrees Fahrenheit and about150 degrees Fahrenheit.
 25. The baking additive of claim 20, wherein thefirst quantity of acidulate and the second quantity of acidulate areblended together in a 1:1 ratio by weight.